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Need to replace power cord but can't get head off to do it. Have removed the two long screws that hold everything together according to schematic. Also removed two screws above the fan assembly and the brushes. The head is still firmly attached to the main body. No screw on the head cap itself as on the newer routers
 

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Paul
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I'm not familiar with that router but I have run into the brushes holding onto the commutator when disassembling tools, especially where they've carved a rut in the comm. Remove the brushes if you haven't already. The only other thing I see is the 'Ring' #209 (C-clip thing).
 

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I am also facing a similar issue related to my router. I have also checked the I am also facing a similar issue related to my router. I have also checked the Facebook page but didn't get an appropriate answer. page but didn't get an appropriate answer.
 

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Had to do something similar, I just cut the cord 2" away from the body and spliced a new and longer cord to it.
 
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